Rothenberger ROWELD E Series User manual

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2
CONTENTS
Brief.......................................................................................................................................................... 2
Special Description................................................................................................................................ 3
Safety....................................................................................................................................................... 4
SHD160 SHD250 SHD315 SHD 355
1. Applicable Range and Technical Parameter.................................................................................8
2.. Descriptions.......................................................................................................................................9
3.. Instruction for Use.......................................................................................................................... 11
4.. Timer and Temperature Controller.............................................................................................. 14
5.. Reference of Welding Standard（DVS2207-1-1995）............................................................16
6.. Malfunctions Analyses and Solutions......................................................................................... 17
7.Electrical draw diagram and Hydraulic schematic diagram....................................................... 21
8.Accessories list................................................................................................................................. 23
Welding parameter.............................................................................................................................. 27
SHD450 SHD500 SHD630 SHD800 SHD1000 SHD1200
1.. Applicable Range and Technical Parameter............................................................................. 38
2. Descriptions......................................................................................................................................39
3. Instruction for Use........................................................................................................................... 41
4. Timer and Temperature Controller............................................................................................... 44
5. Reference of Welding Standard（DVS2207-1-1995）.............................................................47
6. Malfunctions Analyses and Solutions.......................................................................................... 48
7.Electrical draw diagram and Hydraulic schematic diagram....................................................... 52
8.Accessories list................................................................................................................................. 54
Welding parameter.............................................................................................................................. 60
SHDS110 SHDS160A2 SHDS160A4 SHDS160B4 SHDS200A2 SHDS200A4 SHDS200B4
1. Applicable Range and Technical Parameter.............................................................................. 72
2. Descriptions......................................................................................................................................73
3. Instruction for Use........................................................................................................................... 74
4. Timer and Temperature Controller............................................................................................... 76
5.Reference of Welding Standard（DVS2207-1-1995）.............................................................. 78
6. Malfunctions Analyses and Solutions.......................................................................................... 79
7.Electrical draw diagram and Hydraulic schematic diagram....................................................... 83
8.Accessories list................................................................................................................................. 84
Guarantee Clauses..............................................................................................................................87

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Brief
Along with the property of PE material continuous perfecting and raising, PE pipes are
extensively used in gas and water supply, sewage disposal, chemical industry, mine and so
on.
For more than ten years, our factory has been researching and developing SH series plastics
pipe butt fusion machine that is suit for PE, PP, and PVDF. We have fulfilled the techniques
requirements of ISO12176-1. Our products have outstanding features in convenience,
reliability, safety and lower price.
Today, our products include nine kinds and over than 20 types that can be applied to plastics
pipe construction and make fittings in workshop as follow:
* SHS series socket welder * SJC series band saw
* SHDS series manual butt fusion machine* SHG series workshop butt fusion machine
* SHD series butt fusion machine * Series special tools
* SHDA series Auto-butt fusion machine * SHM series saddle fusion machine
This manual is suit for SHD －160/250/315 plastic pipe butt fusion welding machine. It’s
suggested to read and follow carefully the following safety rules and maintenance rules before
operating the machine.

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Special Description
Before operating the machine, anyone should read this description carefully and keep it well
to ensure the equipment and operator’s safety, as well as others’ safety.
2.1 The machine is used to weld pipes made from PE, PP, PVDF and can
not be used to weld material without description, otherwise the machine
may be damaged or some accident may be resulted in.
2.2 Don’t use the machine in a place with potential hazard of explosion
2.3 The machine should be operated by responsible, qualified and trained personnel.
2.4 The machine should be operated on a dry area. The protective measures should be
adopted when it is used in rain or on wet ground.
2.5 The machine is operated by 220V±10%, 50/60 Hz. If extended wire should be used, it
should have enough lead section according its length.
2.6 Before using the machine, fill 46# hydraulic oil. Make sure the hydraulic oil is enough for
working; the oil level should be 2/3 of the tank. Replace the iron oil tank cap by the red plastic
air bleed cap or the pressure can not be hold.

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Safety
3.1 safety marks
The following marks are affixed to the machine:
Hot！Keep distance from parts with this sign, for they
are very hot!
Danger, Electrical shock
Parts with this sign have a danger of electricity leak.
Be careful when working here.
No approaching! Moving parts can crush. Keep
fingers, feet, arms, legs, and head out of the jaw area
between the moving tables.
Caution, injure hand
Caution, heavy
3.2 Precautions for Safety
Take care when operating and transporting the machine according to all the safety rules in this
instruction.
3.2.1 Notice when using
The operator should be responsible and trained personnel.
Completely inspect and maintain the machine per year for the safety and machine’s
reliability.
Dirty and crowed work site would not only lower working efficiency, but cause
accident easily, so it is important to keep work site clean and no other obstacles

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3.2.2 Power
The electricity distribution box should have ground fault interrupter with relevant electricity
safety standard. All safety protection devices are indicated by easily understandable words or
marks.
Earthing: The whole site should share the same ground wire and the ground connection
system should be completed and tested by professional people.
3.2.3 Connection of machine to power
The cable connecting machine to power should be mechanical concussion and chemical
corrosion proof. If the extended wire is used, it must have enough lead section according to its
length.
3.2.4 Storage of electrical equipment
For the min. dangers, all equipment must be used and stored correctly as follows:
※Avoid using temporary wire not complying with standard
※Do not touch electrophorus parts
※Forbid hauling off the cable to disconnect
※Forbid hauling cables for lifting equipment
※Do not put heavy or sharp object on the cables, and control the temperature of cable
within limiting temperature (70℃)
※Do not work in the wet environment. Check if the groove and shoes is dry.
※Do not splash the machine
3.2.5 Check insulation condition of machine periodically
※Check the insulation of cables specially the points extruded
※Do not operate the machine under extreme condition.
※Check if the leakage switch works well at least per week.
※Check the earthing of the machine by qualified personnel
3.2.6 Clean and check the machine carefully
※Do not use materials (like abrasive, and other solvents) damaging the insulation easily
when cleaning the machine.
※Make sure the power is disconnected when finishing job.
※Make sure there is no any damage in the machine before reusing.

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If only following above mentioned, the precaution can work well.
3.2.7 Starting
Make sure the switch of the machine is closed before powering it on.
3.2.8 Tightness of parts
Make sure the pipes are fixed correctly. Ensure that it can move well and prevent it from
sliding down.
3.2.9 Work in environment with hazards
When work in a ditch, check if there is fender which stop the earth or stones from falling down
to the machine, and also check if it has a water or other fluid leaking, if there be, the operator
may get an electric shock.
When lift the machine to ditch, the weight of the machine should be within the rated lifting
weight, and person is forbidden staying under the lifting arm.
Avoid using the machine in the environment full of paint, gas, smoke and deoil, since the
infection of eyes and respiratory tract would be caused.
Do not put the machine in a dirty place.
3.2.12 Personnel safety while working
Remove jewelry and rings, and does not wear loose-fitting clothing avoid wearing shoe lace,
long mustache or long hair that may be hooked into the machine
The following is the operation rules:
---Wear safety groove
---Wear safety shoes
---Dress work clothes
---Wear safety glasses
---Wear earmuffs
3.2.14 Untrained person is not allowed to operate the machine anytime.

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3.3. Potential Dangers
3.3.1 Butt fusion machine controlled by hydraulic unit:
This machine is only operated by professional person or others with a certificate for
operation, otherwise unwanted accident maybe caused.
3.3.2 Heating Plate
The max temperature can reach 270℃, so the following things should be noticed:
------Wear safety groove
-------Never touch the surface of the heating plate
3.3.3 Planing tool
Before shaving the pipes, ends of pipes should be cleaned, especially clean the sand or other
draff crowed around the ends. By doing this, the lifetime of edge can be prolonged, and also
prevent the shavings are thrown out to danger people.
3.3.4 Basic Frame:
Make sure the pipes or fittings are fixed correctly to get the right alignment. When joining
pipes, the operator should keep a certain space to the machine for personnel safety.
Before transporting, make sure all the clamps are fixed well and can not fall down during
transportation.
Follow all the safety marks in the machine.

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SHD160 SHD250 SHD315 SHD 355
1. Applicable Range and Technical Parameter
Type
SHD-160/63
SHD250/63
SHD315/90
SHD355/90
Materials
PE，PP，PVDF
Max.range of diameter
63~160mm
63~250mm
90~315mm
90~355mm
Ambient temp.
－5～45℃
Power supply
～220V±10
Total current
10A
17.5A
22.1A
26.6A
Total power
2.45KW
3.85KW
4.85KW
5.85KW
Include：Heating plate
1KW
2 KW
3KW
4KW
Planing tool motor
0.7KW IP54
1.1 KW IP54
1.1KW IP54
1.1KW
Hydraulic unit motor
0.75 kW IP54
Dielectric resistance
>1MΩ
Max. Pressure
6 MPa
Total section of
cylinders
6.26 cm2
10.98 cm2
20 cm2
20 cm2
Volume of oil box
3L
Hydraulic oil
40～50（kinematic viscosity)mm2/s, 40℃
Undesired sound
<70 dB
Max.Temperature of
heating plate
270℃
Difference in surface
temperature of heating
plate
±5℃
Weight
106 kg
130 kg
202.6 kg
260 kg
* The special voltage is based on the actual voltage.

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2. Descriptions
The machine consists of basic frame, hydraulic unit, heating plate, Planing tool, and support.
Figure .1
1. Heating plate
2.Support
3. Planing tool
4.Hydraulic unit
5. Basic frame
2.1 Basic Frame
Figure .2
1. Main clamp
2. Stub end device
3. Adjust screw
4. Cylinder
5. Connection
2.2 Hydraulic Unit
2.2.1 Hydraulic unit
Figure.3
1. Direction valve
2. Pressure regulation valve
3. Pressure gauge
4. Swing check valve
5. Oil tank
6. Power cable

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2.2.2 Hydraulic unit operation panel
Figure .4
1.Switch
2.Fuse
3. Voltmeter
4. Temperature
controller
5.Timer
6.Endothermic
time button
7.Cooling
time button
8.Direction
valve
9.Pressure
relief valve
10. Pressure
gauge
11.Pressure
regulation valve
2.2.3 Hydraulic unit sockets
Figure 5
1. Planning tool socket
2. Heating plate socket

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3. Instruction for Use
3.1 The whole equipment should be placed on a stable and dry plane to operate.
3.2 Before operation make sure the following things:
The machine is in good conditions
The power complies with the requirements according to the butt fusion machine
Power line is not broken or worn
All instruments are normal
The blades of planning tool are sharp
All necessary parts and tools are available
3.3 Connection and preparation
3.3.1 Connect the basic frame to hydraulic unit by quick couplers.
3.3.2 Connect the heating plate to the hydraulic unit with the special cable.
Connection the cable with electrical box Connection between the cable and heating plate
3.3.3 Install appropriate inserts to frame according to the outside diameter of pipes/fittings.
3.3.4 According to the requirements of fitting and welding process, set the temperature in
temperature controller and set time in timer. (See section 7 this manual).

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3..4 Welding Steps
3.4.1 Pipes
Before welding, firstly, check if the material and its pressure grade are the required ones.
Secondly check if there are scratches or fissures on the surface of pipes/fittings. If the depth
of scratches or fissures exceeds 10% of the wall thickness, cut the section of scratches or
fissures. Clean the pipe end’s surfaces with clean cloth to keep the pipe’s ends clean.
3.4.2 Clamping
Place the pipes/fittings in inserts of frame and keep the ends to be welded be the same length
(no effect on the planning and heating of the pipe). The pipe out of the basic frame should be
supported to the same central axial of clamps. Fasten the screws of clamps to fix the
pipes/fittings.
3.4.3 Adjust the pressure
Open fully the pressure regulation valve completely, lock the swing check valve tightly and
then push forward the direction valve meanwhile adjust the pressure regulation valve till the
cylinder begin to move, at this point the pressure in the system is the drag pressure.
Open the pressure regulation valve completely, lock the swing check valve tightly and then
push forward the direction valve meanwhile adjust the pressure regulation valve to set the
system pressure equals to drag pressure add butting pressure.
3.4.4 Planing
Open the pipes/fittings ends after turning swing check valve anti-clockwise to the end. Put the
planning tool between the pipes/fittings ends and switch it on, close the pipes/fittings ends by
acting on the direction valve meanwhile slowly turn swing check valve clockwise until there
are continuous shavings appearing on both sides. Turn the swing valve anti clockwise to relief
the pressure, in a moment later open the frame, switch off the planing tool and remove it.
Close the pipes/fitting ends and checks the alignment of them. The maximal misalignment
should not exceed 10% of the wall thickness, and it could be improved by loosening or
tightening the screws of clamps. The gap between two pipe ends should not exceed 10% of
wall thickness; otherwise the pipes/fittings should be planed again.
Caution: The shavings thickness should be within 0.2~0.5 mm and it can be adjusted by
adjusting the height of the planning tool blades.

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3.4.5 Heating
Clear the dust or slit on the surface of heating plate (Caution: Don’t damage PTFE layer on
the surface of heating plate.), and make sure the temperature has reached the required one.
Put the heating plate between the pipe ends after it reaches required temperature. Close the
pipes/fittings ends by operating direction valve and raise the pressure to specified pressure by
swinging pressure regulation valve till the bead reaches specified height.
Turn swing check valve anti-clockwise to reduce the pressure (not more than drag pressure)
and turn swing check valve in clockwise direction to the end.
Press the button “T2” , the soaking time begins to count and the time will count down to zero
by second, then the buzzer will buzz（see section 7）
3.4.6 Joining and cooling
Open the frame and take out the heating plate and close two melting ends as quickly as
possible.
Keep the bar of direction valve on the close position for 2~3 minutes, put the bar of direction
valve on middle position and press the button (“T5”) to count cooling time until it is over. At
this point, the machine will give an alarm again. Relief the pressure, loose the screw of clamps
and then take out the jointed pipes.

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4.Timer and Temperature Controller
If one of the parameters is changed, such as outside diameter, SDR or material of pipes, the
soaking time and cooling time should be reset according to the welding standard.
4.1 Timer setting
4.2 Instruction for Use
Press
“set”
The lamp T2is on and the lamp T5is off
Pressing
△or▽
To set soaking time in second.
Press
“set”
The lamp T2is off and the lamp T5is on
Press
△or▽
To set cooling time in second
Press
“Set”
Timer setting is over
Press
“T2”
Press
“T5”
Press
“△”and“▽
”
Alarm when the soaking time counts down to zero.
Alarm when the cooling time counts down to zero
Timer stops

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4.3 Temperature controller setting
（1）Temperature controller setting
Switch on
Press “SET” for more than 4 seconds till “Sd” is shown in the upper window
Press “△” or “▽”key, enter the setting temperature, and press "SET" to confirm
（2）Deviation Correction of temperature Control instrument
Switch on
Press “SET” for more than 3 seconds till “SI” is shown in the upper window
Press “SET” till “SC” is shown in the upper window
Press “△” or “▽”key, enter temperature correction value, press "SET" key to confirm

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5.Reference of Welding Standard（DVS2207-1-1995）
5.1 Because of difference in welding standard and PE material, the time and pressure vary in
different phases of welding. It suggests that the actual welding parameters should be offered
by pipes and fittings’ manufacturers.
5.2 Given welding temperature of pipes made from PE 、PP and PVDF by DVS standard
ranges from180℃to 270℃. Application temperature of heating plate is within 180～230℃,
and its max. surface temperature can reach 270℃.
5.3 Reference standard DVS2207-1-1995
熔接压力
t5
t2
t1
t3
t4
吸热压力
Bead build-up pressure ）Welding pressure =（P1）P3+Drag pressure
Section of welding pipe ends
welding pressure = × 0.15 + Drag pressure（MPa）
Total section of cylinders
Section of welding pipe ends =
3.14 ×(Pipe diameter - Wall thickness）×Wall thickness
Note:The drag pressure is not more than 50% of the welding pressure.
Pipe
diameter
Wall
thickness
Bead
build-up
pressur
e
Bead
height
Soaking
pressure
Soaking
time
Change-
over
time
Pressure
build -up
time
Welding
pressur
e
Cooling time
D
e
P1
H
P2
t2
t3
t4
P3
t5
Bead pressure
Welding pressure
Soaking pressure
Time

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6.Malfunctions Analyses and Solutions
6.1 Frequent joints quality problems analyze:
Visually check：round bead, good joint
Narrow and fall bead. Too high pressure while
welding
Too small bead. Pressure is not enough while
welding
◆There is a ditch between the welding surfaces.
Temperature is not enough or change-over time is too
long while welding.
◆High & low bead. Different heating time or fusion
temperature causes that.
◆Misalignment. Welding under the condition that the
misalignment exceeds 10% of pipe wall thickness
while align the two ends.

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6.2.2 Maintenance & Inspection
Ordinary inspection
Item
Description
Inspect
before
use
First
month
Every 6
months
Every
year
Planning
tool
Mill or replace the blade
Replace the cable if it is broken
Retighten mechanical connections
●
●
●
●
●
Heating
plate
Rejoined the cable and socket
Clean surface of heating plate, recoat PTFE
layer again if necessary
Retighten mechanical connections
●
●
●
●
●
Temp.
control
system
Checkout the temperature indicator
Replace the cable if it is broken
●
●
●
Hydraulic
system
Checkout pressure gauge
Replace seals if the hydraulic unit is leak
Clean the filter
Make sure the oil is enough for operation
Change the hydraulic oil
Replace if the oil hose is breakage
●
●
●
●
●
●
●
●
Basic
Frame
Retighten screws in the end of frame axis
Spray antirust paint again if necessary
●
●
●
●
Power
Supply
Press the testing button of circuit protector
to make sure it can working normally
Replace the cable if it is broken
●
●
●
“●”………… maintenance period

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6.3 Frequent malfunction analyses and solutions
During the using, hydraulic unit and electrical units may appear some problems. Frequent
malfunction is listed as follows:
Please use tools attached, spare parts or other tools with a safety certificate while maintain or
replace parts. Tools and spare parts without safety certificate are forbidden to be used.
Malfunctions of hydraulic unit
No
malfunction
malfunction analyzes
Solutions
1
The pump
motor does not
work
1. switch is fault.
2. Power source is not connected
well.
3. The socket inside connection is
loosen
4. The machine is not grounded
correctly
1. Check the switch
2. Connect the power well
3. Check the connection
4. Check the earthing connection
2
The pump
motor rotate too
slowly with
abnormality
noise
1. The motor is overloaded
2. The motor is fault
3. The oil filter is blocked
4. The working voltage is instable
1. Make sure the motor load is
less that 3 MPa
2. Repair or replace the pump
3. Clean the filter
4. Check the instability of power
3
The cylinder
works
abnormally
1. The direction valve is damaged
2. There is air in system
3. The system pressure is too low
4. The quick coupler is blocked
5. The pressure relief valve is not
locked
1. Replace the direction valve.
2. Move the cylinder several times
to outgo the air.
3. Adjust the system pressure
4. Replace the quick coupler
5. Lock the valve
4
Cylinder leak
1. The oil ring is fault
2. The cylinder or piston is damaged
badly
1. Replace the oil ring
2. Replace the cylinder
5
The pressure
can not be
increased or the
fluctuation is too
big
1. The core of overflow valve is
blocked.
2. The pump is leak.
3. The joint slack of pump is loosened
or key groove is skid.
4. 4. The pressure relief valve is not
locked
1. Clean or replace the core of
over-flow valve
2. Replace the pump
3. Replace the joint slack
4. 4. Lock the valve